2.4 ld9 engine overhaul procedures ... - ion …- back forward -> document id# 589176 2000...

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Engine OverhaulIn order to overhaul, follow the sequence below.

Draining Fluids and Oil Filter Removal1.Engine Flywheel Removal2.Oil Level Indicator and Tube Removal3.Exhaust Manifold Removal4.Intake Manifold Removal5.Crankshaft Balancer Removal6.Engine Front Cover Removal7.Timing Chain, Sprockets, and Tensioner Removal8.Water Pump Removal9.Timing Chain Housing Removal10.Intake Camshaft, Housing and Lifter Removal11.Exhaust Camshaft, Housing and Lifter Removal12.Cylinder Head Removal13.Oil Filter Adapter Removal14.Oil Pan Removal15.Oil Pump Removal16.Balance Shaft Housing Removal17.Piston, Connecting Rod, and Bearing Removal18.Crankshaft Rear Oil Seal and Housing Removal19.Crankshaft and Bearings Removal20.Engine Block Plug Removal21.Engine Block Cleaning and Inspection22.Crankshaft Balancer Cleaning and Inspection23.Engine Flywheel Cleaning and Inspection24.Cylinder Boring and Honing25.Crankshaft and Bearings Cleaning and Inspection26.Piston and Connecting Rod Disassemble27.Piston, Connecting Rod, and Bearings Cleaning and Inspection28.Piston Selection29.Piston and Connecting Rod Assemble30.Camshaft and Housing Cleaning and Inspection31.Timing Chain and Sprockets Cleaning and Inspection32.

Cylinder Head Disassemble33.Cylinder Head Cleaning and Inspection34.Valve Guide Reaming/Valve and Seat Grinding35.Cylinder Head Assemble36.Oil Pump Disassemble37.Oil Pump Cleaning and Inspection38.Oil Pump Assemble39.Engine Front Cover Cleaning and Inspection40.Intake Manifold Cleaning and Inspection41.Exhaust Manifold Cleaning and Inspection42.Oil Pan Cleaning and Inspection43.Balance Shaft Cleaning and Inspection44.Service Prior to Assembly45.Engine Block Plug Installation46.Crankshaft and Bearings Installation47.Crankshaft Rear Oil Seal and Housing Installation48.Piston, Connecting Rod, and Bearing Installation49.Balance Shaft Housing Installation50.Oil Pump Installation51.Timing Balance Shafts to Engine52.Cylinder Head Installation53.Intake Camshaft, Housing and Lifter Installation54.Exhaust Camshaft, Housing and Lifter Installation55.Timing Chain Housing Installation56.Water Pump Installation57.Timing Chain, Sprockets, Tensioner Installation58.Crankshaft Front Cover Oil Seal Installation59.Engine Front Cover Installation60.Oil Pan Installation61.Oil Filter Adapter Installation62.Intake Manifold Installation63.Crankshaft Balancer Installation64.Exhaust Manifold Installation65.Oil Level Indicator and Tube Installation66.Engine Flywheel Installation67.Engine Set-Up and Testing68.



Draining Fluids and Oil Filter Removal

Remove the oil pan drain bolt and allow the oil to drain from the oil pan.1.Remove the oil filter.2.

Remove the coolant jacket drain plug and allow the coolant to drain from the water jacket.3.

Notice

Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fastenersrequiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do notuse paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torqueand joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners inorder to avoid damage to parts and systems.

Install the oil pan drain bolt and the coolant jacket plug.4.Tighten

Tighten the oil pan drain bolt to 26 N·m (19 lb ft).1.Tighten the water jacket plug to 30 N·m (22 lb ft).2.

If cleaning or repairing the engine block it is not necessary to reinstall the plugs.5.



Engine Flywheel RemovalTools Required

J 38122-A Crankshaft Balancer Holder

Important

It may be necessary to remove the chamfer (bevel) from the edge of an 18 mm socket in order to get full socket engagement on the thinheaded flywheel bolts.

Do not orientate the flywheel to the crankshaft. The flywheel is balanced separately from the engine.

Remove the flywheel attaching bolt. Use the J 38122-A to prevent crankshaft rotation.1.Remove the flywheel, if the vehicle has a manual transmission.2.

Remove the flywheel retainer for vehicles with automatic transmission.3.Remove the flywheel, if the vehicle has an automatic transmission.4.Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.5.



Oil Level Indicator and Tube Removal

Remove the tube bracket to the rear cam carrier lift bracket bolt.1.Remove the tube from the block.2.



Exhaust Manifold Removal

Remove the exhaust manifold brace to the manifold bolt.1.

Remove the exhaust manifold heat shield, if the exhaust manifold is being replaced.2.

Remove the exhaust manifold to the cylinder head retaining nuts.3.Remove the exhaust manifold.4.Clean all of the sealing surfaces.5.If the exhaust manifold is being replaced, transfer the following parts:6.

The exhaust manifold nuts1.The exhaust manifold heat shield2.



Intake Manifold RemovalNotice

Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold is made ofa composite plastic and can be damaged if it is removed when the engine is hot.

Remove the throttle body.1.Disconnect the fuel pressure regulator hose.2.

Remove the intake manifold retaining nuts and bolts.3.Remove the intake manifold.4.Remove the intake manifold gasket. The gasket is reusable if the gasket is not damaged.5.

If the intake manifold needs to be replaced, transfer the following parts:6.The throttle body1.The throttle body gasket. The manifold to the throttle body gasket is reusable if the gasket is not damaged.2.



Crankshaft Balancer RemovalTools RequiredJ 38122-A Harmonic Balancer Holder1.J 24420-C Harmonic Balancer Puller2.

Remove the balancer retaining bolt and washer. Use the J 38122-A in order to prevent the crankshaft from rotating when loosening thebolt.

1.

Remove the balancer assembly, using the J 24420-C .2.



Engine Front Cover Removal

Remove the front cover bolts and nuts.1.Remove the front cover.2.Remove the front cover gasket. The gasket is reusable.3.

Remove the front cover oil seal.4.



Timing Chain, Sprockets, and Tensioner Removal

Notice

The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timingsprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrongtiming chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled in the same side facing outat the time of reassembly.

Important

Read the entire procedure before removing the timing chain.

Mark the timing chain and the crankshaft sprocket outer surfaces for reassembly. Ensure that this is done in order to prevent noise andincreased wear on the chain.

1.

Remove the timing chain guides.2.

Remove the tensioner assembly retaining bolts.3.Remove the tensioner shoe. Use a small locking ring plier to engage the hole in the locking tab to remove the shoe from the stud.4.

Remove the timing chain.5.Inspect the parts for wear. Replace the parts as required.6.Replace the timing chain shoe or guides if the scoring exceeds 1.12 mm (0.045 in).7.



Water Pump RemovalTools Required

J 36008-A Camshaft Timing Pins

Important

The timing chain tensioner must be removed to unload chain tension before the water pump is removed. If the tension is not unloaded, thewater pump will become cocked in the timing chain housing and the water pump will be difficult to remove.

Rotate the timing chain sprockets to line up the holes. Install the J 36008-A .1.

Remove the bolts holding the tensioner in place.2.

Remove the water pump cover to the cylinder block bolts.3.Remove the water pump assembly to the timing chain housing nuts.4.Remove the water pump cover assembly.5.Remove the water pump.6.Remove the water pump cover to the water pump assembly bolts.7.Clean and inspect all sealing surfaces.8.Inspect the water pump for cracking.9.



Timing Chain Housing RemovalTools Required

J 39579 Camshaft Gear Holder

Remove the camshaft sprocket retaining bolts and washers. Use the J 39579 to hold the sprockets when removing the bolts.1.Remove the camshaft sprockets. The sprockets are interchangeable. No marking is required.2.Remove the 4 oil pan bolts.3.

Remove the timing chain housing to camshaft housing bolts.4.Remove the timing chain housing to block bolts.5.Remove the timing chain housing.6.Remove the timing chain housing gaskets.7.



Intake Camshaft, Housing and Lifter Removal

Important

Use this procedure only if the camshaft or lifters are going to be removed.1.Read the entire procedure before removing the camshaft housing.2.Replace the camshaft housing to cylinder head gasket any time the camshaft housing to cylinder head bolts are loosened orremoved.

3.

Ensure that the valve lifters are kept together and identified during disassembly. Do this in order to ensure that the valve lifters areinstalled in the original location.

4.

Important

Use the reverse of the tightening procedure when loosening the camshaft housing to the cylinder head retaining bolts. Leave the boltsloosely in place to hold the camshaft housing while separating the camshaft cover from the housing.

Remove the camshaft housing cover to the camshaft housing retaining bolts.1.Remove the remaining camshaft housing to the cylinder head retaining bolts.2.Remove the camshaft sensor bolt.3.Remove the camshaft sensor.4.

Important

Push the cover off of the housing. Remove the cover by threading four of the housing to head retaining bolts into the tapped holes in thecamshaft housing cover.

Tighten the bolts evenly in order to prevent the cover from binding on the dowel pins.

Remove the loosely installed camshaft housing to head bolts.5.Remove the camshaft housing cover. Discard the seals.6.Loosely reinstall one camshaft housing to the cylinder head bolt in order to retain the housing during camshaft and lifter removal.7.Remove the camshaft. Be careful not to damage the camshaft or journals.8.

Important

Keep the valve lifters in order so they can be reinstalled in the same location.

Remove the valve lifters.9.Follow the below guidelines in order to minimize lifter bleed down:10.

Store the lifters upside down on a level surface. Keep the camshaft contact surface down.1.The lifters can also be submerged in clean engine oil.2.

Important

The valve lifters are not repairable. Replace the lifters if the lifters are faulty. Do not get prelube on the camshaft cover seals becausethe seals will swell.

1.

Coat the lifter with Camshaft and Lifter Prelube GM P/N United States 12345501, GM P/N Canada 992704 or the equivalentbefore installation.

2.

If new lifters are installed, add Engine Oil Supplement GM P/N United States 1052367, GM P/N Canada 992869 or an equivalent to theengine oil.

11.

Remove the camshaft housing.12.Remove the camshaft housing gasket.13.



Exhaust Camshaft, Housing and Lifter Removal

Important

Read the entire procedure before removing the camshaft housing.1.The camshaft housing to the cylinder head gasket must be replaced any time the camshaft housing to the cylinder head bolts areloosened or removed.

2.

During disassembly, be sure that the valve lifters are kept together and identified in order so that the valve lifters may be reinstalledin their original locations.

3.

Remove the exhaust camshaft rear cover.1.Remove the exhaust camshaft rear cover gasket.2.

Important

Use the reverse of the tightening procedure when loosening the camshaft housing to the cylinder head retaining bolts.

Remove the exhaust camshaft housing to the cylinder head bolts.3.

Important

Leave 2 bolts loosely in place to hold the camshaft housing while separating the camshaft cover from the housing.

Push the cover off the camshaft housing by threading four of the housing to the head retaining bolts into the tapped holes in the camshaftcover.

4.

Important

Tighten the bolts evenly to prevent the cover from binding on the dowel pins.

Remove the two loosely installed camshaft housing to the head bolts.5.Remove the camshaft cover. Discard the seals.6.Loosely install one camshaft housing to the cylinder head bolt to retain the housing during the camshaft and lifter removal.7.Remove the camshaft. Be careful not to damage the camshaft or journals.8.Remove the valve lifters. Keep the valve lifters in order so that the valve lifters may be reinstalled in the same location from which theywere removed.

9.

Do one of the following to minimize lifter bleed down:10.Store the lifters upside down on a level surface. Keep the camshaft contact surface down.1.Store the lifters submerged in clean engine oil.2.

Important

The valve lifters are not repairable. Replace the lifters if the lifters are faulty. Do not get prelube on the camshaft cover seals becausethe seals will swell.

1.

Coat the lifter with Camshaft and Lifter Prelube GM P/N United States 12345501, GM P/N Canada 992704 or an equivalent beforeinstallation.

2.

If new lifters are installed, add Engine Oil Supplement GM P/N United States 1052367, GM P/N Canada 992869 or an equivalent to theengine oil.

11.

Remove the camshaft housing.12.Remove the camshaft housing gasket.13.



Cylinder Head RemovalTools Required

J 38188 Cylinder Head Broken Bolt Extractor Kit

Remove the cylinder head to the block bolts. Follow the reverse of the tightening sequence.1.Remove the cylinder head.2.Remove the cylinder head gasket.3.

Notice

Gasket and sealant material must be removed from the component's sealing surfaces before reassembly. Proper gasket and sealant removalis crucial and requires that the component sealing surfaces are not damaged during cleaning. Use only a plastic or wood gasket scrapersuch as J 28410. Appropriate chemical agents can be used to dissolve gasket and/or sealant materials when working on an individualunassembled component. The components exposed to the chemical agents must be rinsed with cleaning solvent in order to neutralize thechemical agent. Do not use abrasive paper, pads, or wire brush/wheel in order to clean sealing surfaces. Abrasive paper, pads, or wirebrush/wheel will damage the sealing surfaces and produce fine grit residue that will contaminate the engine and engine oil. Failure to useproper cleaning methods may lead to engine damage.

Important

Do not use any other method or technique to clean these gasket surfaces.

Clean all of the gasket surfaces.4.Use the following procedures when cleaning the cylinder head and cylinder block surfaces:5.

Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge any surface.1.Use a new razor blade for each cylinder head and cylinder block.2.

Hold the razor blade as parallel to the gasket surface as possible.3.

Important

Do not use a tap to clean the cylinder head bolt holes.

Clean the old sealer/lube and dirt from the bolt, the studs, and the bolt holes.6.Clean the bolt holes using a nylon bristle brush.7.

Caution

Wear safety glasses to avoid injury when using compressed air or any cleaning solvent. Bodily injury may occur if fumes areinhaled or if skin is exposed to chemicals.

When cleaning the cylinder head bolt holes 1-8 use a suitable commercial spray liquid solvent and compressed air from an extended-tipblow gun to reach the bottom of the holes.

8.

Remove any broken long cylinder head bolts using the J 38188 .9.



Oil Filter Adapter Removal

Remove the oil filter.1.Ensure that the gasket is removed with the filter.2.

Remove the oil filter adapter.3.

Remove the oil filter bypass valve using a screwdriver or punch to pry the valve out.4.Clean the oil filter mounting surface.5.



Oil Pan Removal

Remove the oil pan bolts.1.Remove the oil pan. Reuse the oil pan gasket if the pan is not damaged.2.Inspect the oil pan gasket for damage before reusing the gasket. Replace the gasket if necessary.3.



Oil Pump Removal

Remove the balance shaft chain cover.1.Remove the balance shaft chain guide.2.Remove the oil pump bolts.3.

Remove the oil pump cover.4.

Remove the oil pump from the balance shaft assembly.5.



Balance Shaft Housing RemovalTools Required

J 39579 Camshaft Gear Holder

Check the balance shaft end play prior to disassembling the balance shaft housing.1.Set up the indicator to read off the back of the shafts.2.Press against the shafts and note their movement.3.Compare the shafts against specifications.4.If the shafts do not meet specifications, check the thrust plate for wear. Replace the thrust plate if the plate is worn.5.If the end play does not meet specifications and the thrust plate is not worn, replace the balance shafts.6.Remove the balance shaft chain cover.7.Loosen, but do not remove the balance shaft chain guide.8.

Use the J 39579 to hold the crankshaft.9.

Notice

The balance shaft driven sprocket bolt is left hand threaded and must be loosened by rotating it in a clockwise direction. If the bolt is notloosened in a clockwise direction, it may break.

Remove the balance shaft driven sprocket bolt.10.

Important

Mark the surface of the driven sprocket if the sprocket is going to be reused. This will insure that the chain continues to ride on the sametooth surface. Either surface can be placed against the shaft, if a new driven sprocket is installed.

Remove the driven sprocket from the shaft.11.Remove the balance shaft assembly fasteners and remove the assembly to the bench.12.Clean all of the balance shaft housing parts in cleaning solvent. Remove the varnish, sludge and dirt.13.Inspect the housings for the following conditions:14.

Cracks1.Scored bearing bores2.Damaged threaded holes3.

Important

Replace the entire assembly if the housings are damaged in any way.

Clean all of the balance shaft chain cover parts in cleaning solvent. Remove the varnish, sludge and dirt.15.Inspect the cover for the following conditions:16.

Cracks1.Broken guides2.Worn guides3.



Piston, Connecting Rod, and Bearing Removal

Rotate the crankshaft to a position where the connecting rod nuts are the most accessible.1.Mark the connecting rod and cap with the cylinder position. Also mark the orientation. This will ensure the caps and connecting rods arere-assembled properly.

2.

Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands.3.Remove the connecting rod nuts.4.Remove the connecting rod cap.5.Install thread protectors (3 in length of 3/8 inch ID hose) on the connecting rod bolts before removing the piston and connecting rodassembly.

6.

Remove the piston and connecting rod assembly.7.


Crankshaft Rear Oil Seal and Housing Removal

Remove the seal housing to the block bolts.1.Remove the oil seal housing.2.Remove the gasket.3.

Notice

Properly support the seal housing to prevent damage to the seal during removal. Damage to the seal will result in an oil leak.

Use the following procedure in order to remove the oil seal:4.Support the oil seal housing for oil seal removal using 2 wood blocks of equal thickness.A.With the wood blocks on a flat surface, position the seal housing and the blocks. This will allow for the transmission side of the oilB.

seal housing to be supported across the dowel pin and the center bolt holes on both sides of the oil seal opening.Drive the crankshaft seal evenly out of the transmission side of the oil seal housing. Use a small chisel in the relief grooves on thecrankshaft side of the oil seal housing.

C.



Crankshaft and Bearings Removal

Remove the crankshaft position sensor. Inspect the position sensor for damage. Replace the sensor if necessary.1.Remove the main bearing bolts.2.Remove the bearing caps.3.

Notice

Remove the crankshaft carefully in order to avoid damaging the crankshaft journals, the rod, the main bearing inserts, or the connectingrods.

Remove the crankshaft from the block.4.Remove the bearing inserts from the block.5.

Clean the oil, sludge, and carbon.6.Inspect the oil passages for obstructions.7.Inspect the keyway.8.Inspect the threads.9.Inspect the bearing journals and the thrust surfaces for the following conditions:10.

Cracks1.Chips2.Gouges3.Roughness4.Grooves5.Overheating (discoloration)6.

Inspect the corresponding bearing inserts for imbedded foreign material. If foreign material exists, find the cause and repair the cause.11.

Important

Replace the crankshaft if cracks, severe gouges, or burned spots are found. Slight roughness may be removed with a fine polishing clothsoaked in clean engine oil. Burrs may be removed with a fine oil stone.

Measure the crankshaft journals. Use a micrometer or dial indicator to measure the taper and runout. Note the result for the later selectionof bearing inserts. If not within limits the crankshaft must be replaced.

12.

Note the location of the main bearing high spots. If they are not in line, the crankshaft is bent and must be replaced.



Engine Block Plug Removal

Remove the water jacket drain plug.1.

Remove the oil flow check valve.2.

Remove the oil passage plug from the front of the engine block.3.

Remove the oil passage plug from the timing chain tensioner gallery.4.

Remove the rear oil passage plug.5.

Remove the oil passage plug from the right side of the engine block.6.

Remove the timing chain housing alignment pins.7.

Remove the oil pan alignment pins.8.



Engine Block Cleaning and InspectionTools RequiredJ 8087 Cylinder Bore Gauge1.J 7872 Magnetic Base Dial Indicator Set2.

Clean the sealing material from the gasket mating surfaces.1.Boil the engine block in caustic solution.2.Flush the engine block with clean water or steam.3.Clean the oil passages.4.Clean the blind holes.5.Spray the cylinder bores and the machined surfaces with engine oil.6.Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and install thread inserts. Refer toThread Repair .

7.

Use a straight edge and a feeler gage to check the deck surface for flatness. Carefully machine minor irregularities. Replace the block ifmore than 0.254 mm (0.010 in) must be removed.

8.

Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.9.

Inspect the mating surfaces of the transmission case.10.

Notice

A broken flywheel may result if the transmission case mating surface is not flat.

Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole bosses:11.Temporarily install the crankshaft. Measure the crankshaft flange runout using the J 7872 .A.Hold the gauge plate flat against the crankshaft flange.B.Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0.C.Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.203 mm (0.008 in).D.Recheck the crankshaft flange runout if the readings vary more than 0.203 mm (0.008 in).E.

Inspect the crankshaft main bearing bores. Use the J 8087 to measure the bearing bore concentricity and alignment at the followinglocations:

12.

The camshaft1.The crankshaft2.

Important

Recondition the engine block with the crankshaft bearing cap bolts installed and tightened to specification.

Ensure that the crankshaft bearing caps are installed correctly. The arrows should point toward the front of the engine.13.Replace the engine block if the crankshaft bearing bores are out of specification.14.

Use the J 8087 to inspect the cylinder bores. Inspect for the following items:15.Wear1.Taper2.Runout3.Ridging4.

Important

If the bore is worn beyond the limits, refit the bore with oversized pistons. Select the smallest available oversize piston.

Leave sufficient material to allow honing when fitting the piston.16.



Crankshaft Balancer Cleaning and Inspection

Clean the crankshaft balancer in solvent.1.Clean the belt grooves of all dirt or debris with a wire brush.2.

Caution

Wear safety glasses in order to avoid eye damage.

Dry the crankshaft balancer with compressed air.3.Inspect the crankshaft balancer for the following:4.

Worn, grooved, or damaged hub seal surface A crankshaft balancer hub seal surface with excessive scoring, grooves, rust or otherdamage must be replaced. Minor imperfections on the hub seal surface may be removed with polishing compound or fine grade

1.

emery cloth.

Important

In order for the belt to track properly, the belt grooves should be free of all dirt or debris.

Dirty or damaged belt grooves The balancer belt grooves should be free of any nicks, gouges, or other damage that may not allowthe belt to track properly. Minor imperfections may be removed with a fine file.

2.

Worn, chunking, or deteriorated rubber between the hub and pulley3.



Engine Flywheel Cleaning and Inspection

Clean the flywheel in solvent.1.

Caution


Dry the flywheel with compressed air.2.Inspect the manual transmission flywheel for the following conditions:3.

Damaged ring gear teeth1.Loose or improperly positioned ring gear The ring gear has an interference fit onto the flywheel and should be positionedcompletely against the flange of the flywheel.

2.

A scored, grooved, or damaged friction surface3.

Inspect the automatic transmission flywheel for the following conditions:4.Damaged ring gear teeth1.Stress cracks around the flywheel-to-crankshaft bolt hole locations2.

Important

Do not attempt to repair the welded areas that retain the ring gear to the flywheel plate. Install a new flywheel.

Welded areas that retain the ring gear onto the flywheel for cracking

3.



Cylinder Boring and HoningTools Required

J 8087 Cylinder Bore Gauge

Measure the cylinder bore for out-of-round and taper.1.Measure dimension (1) at 13 mm (1/2 in) below the head gasket surface. Measure dimension (2) at 100 mm (4 in) below the head gasketsurface.

2.

Measure the cylinder bores by setting the J 8087 at zero in the cylinder at the point of the desired measurement. Lock the dial indicator atzero before removing the dial from the cylinder. Measure across the gauge contact points with an outside micrometer, with the gauge at thesame zero setting as when the gauge was removed from the cylinder.

3.

If dimension (1) is larger than dimension (2) by 0.13 mm (0.005 in), bore the cylinder for oversize piston and rings.4.If relatively few bores require correction, do not rebore all the cylinders to the same oversize in order to maintain engine balance.1.All oversize service pistons are held to the same weights as the standard size pistons.2.

Fine vertical scratches made by the ring ends do not, by themselves, cause excessive oil consumption. Do not hone the cylinder in order toremove these scratches.

5.

If the bore is glazed but otherwise serviceable, lightly break the glaze with a hone. Replace the piston rings. Refer to Piston andConnecting Rod Installation.

6.

The honing stones must be clean, sharp, and straight.1.Move the hone slowly up and down to produce a 45 degree cross hatch pattern.2.Clean the bore thoroughly with soap and water.3.Dry the bore.4.Rub clean engine oil in the bore.5.Remeasure the bore.6.

If honing is not required, clean the cylinder bores with hot water and detergent. Apply clean engine oil to the bore after washing anddrying the bore.

7.



Crankshaft and Bearings Cleaning and InspectionTool RequiredJ 7872 Magnetic Base Dial Indicator Set1.J 8087 Cylinder Bore Gauge2.

Important

Use care when handling the crankshaft. Avoid damage to the bearing surfaces or the lobes of the crankshaft position reluctor ring.Damage to the teeth of the crankshaft position reluctor ring may effect OBD II system performance.

Clean the crankshaft of the following elements:1.

Oil1.Sludge2.Carbon3.

Thoroughly clean all oil passages and inspect for restrictions or burrs.2.

Caution


Dry the crankshaft with compressed air.3.

Important

Reluctor ring teeth should not have imperfections on the rising or falling edges.

Imperfections of the reluctor ring teeth may effect OBD II system performance.

Perform a visual inspection of the crankshaft for damage.4.

Inspect the crankshaft journals for wear (1).5.Journals should be smooth with no signs of scoring, wear, or damage.Inspect the crankshaft journals for grooves or scoring (2).6.Inspect the crankshaft journals for scratches or wear (3).7.Inspect the crankshaft journals for pitting or imbedded bearing material (4).8.

Inspect the woodruff keys (crankshaft balancer) (1), the keyway (2), and the threaded hole (3) for damage.9.

Measure the crankshaft journals for out-of-round. Refer to Engine Mechanical Specifications .10.Measure the crankshaft journals for taper. Refer to Engine Mechanical Specifications .11.

Using wooden V blocks, support the crankshaft on the front and rear journals.12.Use the J 7872 in order to measure the crankshaft runout at the front and rear intermediate journals. Refer to Engine Mechanical Specifications .

13.

Use the J 7872 in order to measure the runout of the crankshaft rear flange. Refer to Engine Mechanical Specifications.14.Replace or repair the crankshaft if the measurements are not within specifications.

In order to properly measure the crankshaft end play, the crankshaft, the crankshaft bearings, the crankshaft bearing caps, and thefasteners must be installed into the engine block and the bolts and studs tightened to specifications.

15.

Firmly thrust the end of the crankshaft first rearward then forward. This will line up the rear crankshaft bearing and the crankshaftthrust surfaces.

A.

With the crankshaft pushed forward, insert a feeler gauge between the crankshaft and the crankshaft bearing surface and thenmeasure the clearance. Refer to Engine Mechanical Specifications .

B.

If the correct end play cannot be obtained, verify that the correct size crankshaft bearing has been installed.C.Inspect the crankshaft for binding. Turn the crankshaft to check for binding. If the crankshaft does not turn freely, loosen thecrankshaft bearing bolts and studs, one crankshaft bearing cap at a time, until the tight crankshaft bearing is located.

D.

Burrs on the crankshaft bearing cap, foreign matter between the crankshaft bearing and the engine block or the crankshaft bearingcap, or a faulty crankshaft bearing could cause a lack of clearance at the crankshaft bearing.

Inspect the crankshaft bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue.16.

Inspect the crankshaft bearings for excessive scoring or discoloration.17.Inspect the crankshaft bearings for dirt or debris imbedded into the crankshaft bearing material.18.

Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the bearing.19.If the lower half of the bearing is worn or damaged, both the upper and lower halves of the crankshaft bearing should be replaced.Generally, if the lower half of the crankshaft bearing is suitable for use, the upper half of the crankshaft bearing should also be suitable foruse.

Important

If cracks, severe gouges or burned spots are found, the crankshaft must be replaced. Slight roughness may be removed with a finepolishing cloth soaked in clean engine oil. Burrs may be removed with a fine oil stone.

Inspect the crankshaft bearing journals and the crankshaft thrust surfaces for the following conditions:20.Cracks1.Chips2.Gouges3.Roughness4.Grooves5.Overheating (discoloration)6.

Inspect the corresponding crankshaft bearings for embedded foreign material and determine the source.21.

Important

Note the location of the crankshaft main bearing high spots. If they are not in line, the crankshaft is bent and must be replaced.

Inspect the crankshaft bearings for uneven side-to-side wear. This may indicate a bent crankshaft or a tapered bearing journal.22.

Notice

Do not scrape, shim, or file bearing inserts. If the bearing surface of the insert is touched with bare fingers, the skin oil and acids will etchthe bearing surface.

Important

The crankshaft bearings are of the precision insert type. The crankshaft bearings are available in standard and various undersizes.

Inspect the outer surfaces of the crankshaft bearings for the following conditions:23.Wear - surface wear indicates either movement of the insert or high spots in the surrounding material (spot wear).1.Overheating or discoloration2.Looseness or rotation indicated by flattened tangs and wear grooves3.

Inspect the thrust surfaces of the main thrust bearing for the following conditions:24.Wear1.Grooving (Grooves are caused by irregularities of the crankshaft thrust surface.)2.

Important

If crankshaft bearing failure is due to other than normal wear, investigate the cause. Inspect the crankshaft or connecting rod bearingbores.

Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure:25.Tighten the bearing cap to specification.A.Measure the bearing bore for taper and out-of-round using the J 8087 . No taper or out-of-round should exist.B.

Measuring Crankshaft Bearing Clearances (Micrometer Method)

Measure the bearing clearance to determine the correct replacement bearing insert size. There are two methods to measure bearing clearance.Micrometer method gives more reliable results and is preferred.

Micrometer method yields measurement from which the bearing clearance can be computed.

Important

Do not mix inserts of different nominal size in the same bearing bore.

Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements.1.Measure the crankshaft bearing journal taper and runout. 2.Install the crankshaft bearing inserts. Tighten the bearing cap bolts to specification.3.Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.4.Measure the crankshaft main bearing inside diameter with an inside micrometer.5.Select a set of bearing inserts that will produce the desired clearance.6.If the specified clearances cannot be met, the crankshaft journals must be reconditioned and undersized bearing inserts installed.7.

Measuring Crankshaft Bearing Clearances (Plastic Gauge Method)

Plastic gauge method yields the bearing clearance directly.

Plastic gauge method does not give any indication of bearing run-out.

Important

Do not mix inserts of different nominal size in the same bearing bore.

Clean the used bearing inserts.1.Install the used bearing inserts.2.Place a piece of gauging plastic across the entire bearing width.3.Install the bearing caps.4.

Notice

In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into thecylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull thecrankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap.

Install the bearing cap bolts to specification.5.

Important

Do not rotate the crankshaft.

Remove the bearing cap, leaving the gauging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to thebearing cap.

6.

Measure the gauging plastic at the widest point with the scale printed on the gaging plastic package.7.Remove the gauging plastic.8.Select a set of bearing inserts that will produce the desired clearance.9.

Measuring Connecting Rod Bearing Side Clearance

Insert a feeler gauge between the connecting rod caps and measure the connecting rod side clearance. Refer to Engine Mechanical Specifications .

1.

The connecting rod side clearances may also be measured with a dial indicator set.2.



Piston and Connecting Rod DisassembleCaution

Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury.

Disassemble the piston rings. Use a suitable tool in order to expand the rings. The piston rings must not be reused.1.

Important

Two retainers hold the piston pins in place. No special tools are required to remove or install the retainers or the piston pins. If theretainers are not damaged, reuse the retainers. Ensure that the piston pin is not damaged.

Remove the piston pin retaining clips.2.Remove the piston pin.3.



Piston, Connecting Rod, and Bearings Cleaning and InspectionConnecting Rod Measurement

Clean the connecting rods in solvent and dry with compressed air.1.Inspect the connecting rods for the following conditions:2.

Signs of being twisted, bent, nicked, or cracked1.Scratches or abrasion on the rod bearing seating surface2.

If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with a light emery paper. DO NOTscrape the rod or rod cap.

3.

Measure the piston pin to connecting rod bore using the following procedure:4.Using an outside micrometer, take two measurements of the piston pin in the area of the connecting rod contact.A.Using an inside micrometer, measure the connecting rod piston pin bore.B.

Subtract the piston pin diameter from the piston pin bore diameter.C.The clearance should not be more than 0.032 mm (0.0013 in).D.

If there is excessive clearance, replace the piston pin.5.If there is still excessive clearance, replace the connecting rod.6.If there is evidence of pin bore or pin scoring, replace the rod and pin assembly.7.

Piston Measurement

Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.1.Clean the piston ring grooves. Ensure that the oil ring holes and slots are clean.2.Inspect the pistons for the following conditions:3.

Cracked ring lands, skirts, or pin bosses1.Ring grooves for nicks, burrs that may cause binding2.Warped or worn ring lands3.Eroded areas at the top of the piston (1)4.Scuffed or damaged skirts (2)5.Worn piston pin bores (3)6.

Replace pistons that show any signs or damage or excessive wear.4.Measure the piston pin bore to piston pin clearances using the following procedure:5.

Piston pin bores and pins must be free of varnish or scuffing.A.Use an outside micrometer to measure the piston pin in the piston contact areas.B.Using an inside micrometer, measure the piston pin bore.C.Subtract the measurement of the piston pin bore from the piston pin. The clearance should be within 0.002-0.011 mm(0.00008-0.00043 in).

D.

If the clearance is excessive, determine which component is out of specification.E.

Measure the piston ring end gap using the following procedure:6.Place the piston ring in the area of the bore where the piston ring will travel (approximately 25 mm or 1 inch down from the decksurface). Ensure that the ring is square with the cylinder bore by positioning the ring with the piston head.

A.

Measure the end gap of the piston ring with feeler gages. Compare the measurements with those provided below:B.The top compression ring end gap should be 0.15-0.30 mm (0.006-0.012 in).1.The second compression ring end gap should be 0.25-0.40 mm (0.0098-0.0157 in).2.The oil ring end gap should be 0.25-0.76 mm (0.0098-0.0299 in).3.

If the clearance exceeds the provided specifications, the piston rings must be replaced.C.Repeat the procedure for all the piston rings.D.

Measure the piston ring side clearance using the following procedure:7.Roll the piston ring entirely around the piston ring groove. If any binding is caused by a burr on the corner of the ring groove,carefully dress the groove corner with a fine file. If any binding is caused by a distorted piston ring, replace the ring.

A.

With the piston ring on the piston, use feeler gages to check clearance at multiple locations.B.The clearance between the surface of the top piston ring and the ring land should be no greater than 0.080 mm (0.0031 in).C.If the clearance is greater than specifications, replace the piston ring.D.If the new ring does not reduce the top ring side clearance to 0.080 mm (0.0031 in) or less, install a new piston.E.

The top compression ring may be installed with either side up. There is a locating dimple on the 2nd compression ring near the end foridentification of the top side. Install the 2nd compression ring with the dimple facing up.

8.

The clearance between the surface of the second piston ring and the ring land should be no greater than 0.070 mm (0.0028 in).9.If the new ring does not reduce the clearance to 0.070 mm (0.0028 in) or less, install a new piston.10.

Measure piston width using the following procedure:11.Using an outside micrometer, measure the width of the piston 42 mm (1.65 in) above the bottom of the piston skirt at the thrustsurface perpendicular to the centerline of the piston pin.

A.

Compare the measurement of the piston to its original cylinder by subtracting the piston width from the cylinder diameter.B.The proper clearance specification for the piston is 0.026-0.078 mm (0.0010-0.0031 in).C.

If the clearance obtained through measurement is greater than these specifications and the cylinder bores are within specification, replacethe piston.

12.



Piston SelectionTools Required

J 8087 Cylinder Bore Gauge

Important

Measurements of all components should be taken with the components at normal room temperature.

For proper piston fit, the engine block cylinder bores must not have excessive wear or taper.

A used piston and pin set may be reinstalled if, after cleaning and inspection, they are within specifications.

Inspect the engine block cylinder bore.1.Refer to Engine Block Cleaning and Inspection .Inspect the piston and the piston pin.2.Refer to Piston, Connecting Rod, and Bearings Cleaning and InspectionUse the J 8087 to measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore.3.

Measure the J 8087 with a micrometer and record the reading.4.

With a micrometer or caliper at a right angle to the piston, measure the piston 11 mm (0.437 in) from the bottom of the skirt.5.Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance.6.For proper piston-to-bore clearance.7.Refer to Engine Mechanical Specifications .If the proper clearance cannot be obtained, select another piston and measure for the clearances.8.If the proper fit cannot be obtained, hone the cylinder bore or replace the cylinder block.9.When the piston-to-cylinder bore clearance is within specifications, mark the top of the piston using a permanent marker for installation tothe proper cylinder.

10.

Refer to Separating Parts .



Piston and Connecting Rod Assemble

Important

Install the piston onto the connecting rod with the arrow oriented toward the front of the engine.

The oil squirt hole at the lower end of the connecting rod must face the exhaust side of the piston.

Assemble the connecting rod and the piston.1.

Notice

Install the piston pin retainers correctly in the retaining groove during assembly in order to avoid engine damage.

Use the following procedure in order to assemble the piston pin and the retainer:2.Coat the piston pin with oil.A.Install one side of one piston pin retainer into the retaining groove. Rotate the retainer until it is fully seated in the groove.B.Install the connecting rod and the piston pin.C.Push the piston pin until the pin bottoms in the previously installed retainer.Install the second piston pin retainer.D.Ensure that the piston moves freely.E.

Notice

Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary.

Install the following components of the oil control ring assembly (bottom ring):3.The expanderA.The lower oil control ringB.The upper oil control ringC.Oil control ring gaps should be oriented 180° apart.

Install the lower compression ring (second ring). Place the manufacturer's mark facing up.4.Install the upper compression ring (top ring).5.



Camshaft and Housing Cleaning and Inspection

Inspect the valve lifters for scoring where the valve lifters contact the camshaft.1.Inspect the camshaft journals and lobes for wear or scoring (1, 2).2.Inspect the camshaft sprocket bolt holes for damaged threads (3).3.Inspect the camshaft sprocket alignment pin for damage and straightness (4).4.

Inspect the camshaft housing and cover for scoring in lifter bores and camshaft journals.5.Clean the camshaft housing and cover.6.

Wash the camshaft housing and cover in solvent.1.Remove all traces of RTV from the power steering pump seal area on the intake camshaft housing and cover.2.Inspect the camshaft housing and cover for cracks or other signs of damage.3.



Timing Chain and Sprockets Cleaning and Inspection

Inspect the timing chain guides for cracking or wear.1.Replace the timing chain guides if wear exceeds 1.12 mm (0.045 in).2.

Inspect the timing chain tensioner shoe for wear.3.Inspect the retaining tab for wear or damage. Replace components as necessary.4.Replace the timing chain tensioner shoe if wear exceeds 1.12 mm (0.045 in).5.

Inspect the timing chain and sprockets for wear.6.Inspect the camshaft sprocket faces for signs of movement.7.Inspect the alignment pin holes in the camshaft for cracking or damage.8.Inspect the camshaft sprocket teeth and chain for signs of excessive wear, chipping, or seizure of the timing chain links.9.



Cylinder Head DisassembleTools RequiredJ 8062 Valve Spring Compressor1.J 36017 Valve Guide Seal Remover2.

Remove the coolant outlet.1.Remove the O-ring.2.Remove valve train components.3.

Important

Ensure that the valve train components are kept together and identified in order for proper re-installation in their original position.

Compress the valve spring, using the J 8062 .4.

Remove the valve keys.5.Slowly release the J 8062 from the valve spring assembly.6.Remove the valve retainer.7.Remove the valve spring.8.Remove the valve spring seat (exhaust only).9.

Notice

Do not damage the valve guide. Remove any burrs that have formed at the key groove by chamfering the valve stem with an oil stone or afile.

Remove the valve seal, using the J 36017 .10.Remove the valve rotator (intake only).11.Remove the valve.12.Remove the remaining valves.13.



Cylinder Head Cleaning and InspectionValve Cleaning and Inspection

Important

Do not scratch the valve stem with the wire brush.

Clean the valves of carbon, oil, and varnish. Carbon can be removed with a wire brush. Varnish can be removed by soaking the valves inParts Immersion Solvent GM P/N United States 12345368, GM P/N Canada 10953514 or an equivalent.

1.

Clean the valve guides.2.Inspect the valve stem for wear. The valve tip may be reconditioned by grinding.3.Follow the grinder manufacturer's instructions. Ensure that the new surface is perpendicular to the valve stem.4.Inspect the valve keeper groove for chipping or wear. Replace the valve if chipped or worn.5.Inspect the valve face for burning or cracking. If pieces are broken off, inspect the corresponding piston and cylinder head area fordamage.

6.

Inspect the valve stem for burrs and scratches. Burrs and minor scratches may be removed with an oil stone.7.Inspect the valve stem for straightness and the valve head for bending or distortion. Use V blocks. Bent or distorted valves must bereplaced.

8.

Clean the deposits from the valve face. Inspect the valve face for grooving.9.Replace the valve if the face is grooved. Valve faces cannot be machined. If worn or damaged, the valves must be replaced.10.The valves may be lightly lapped to the valve seats.11.

Cylinder Head and Gasket Surface Cleaning and Inspection

Use the following procedure to remove the cylinder head cup plugs:1.Obtain a suitable self-threading screw.A.Drill a hole in the plug.B.Install the self-threading screw.C.Pry out the plug and discard it.D.Remove the spark plugs.E.

Inspect the cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has failed, use the following faults todetermine the cause:

2.

Improper installation1.Loose or warped cylinder head2.Missing, off location or not fully seated dowel pins3.Corrosion in the seal area around the coolant passages4.Chips or debris in the cylinder head bolt holes5.Bolt holes in the cylinder block not drilled or tapped deep enough6.Other7.

Inspect the cylinder head gasket surface.3.The cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in) band around each combustion chamber (1).1.Replace the cylinder head if the area between the valve seats is cracked (2).2.Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each combustion chamber (3).3.

Clean the cylinder head bolts.4.

Important

Do not use a wire brush on any gasket sealing surface.

Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.5.Clean the valve guides.6.Clean the threaded holes. Use a nylon bristle brush.7.Clean the remains of the sealer from the plug holes.8.Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools.9.Replace all suspect bolts.10.

Important

Do not attempt to weld the cylinder head. Replace the cylinder head instead.

Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.11.

Inspect the cylinder head deck, the intake, and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned byparallel grinding.

12.

Use the following steps to determine the amount of reconditioning needed:13.If the warpage is less than 0.076 mm (0.003 in), reuse the cylinder head, but do not resurface.1.If the warpage is between 0.076 mm (0.003 in) and 0.25 mm (0.010 in), resurface the cylinder head before reusing.2.If the warpage is over 0.25 mm (0.010 in), discard the cylinder head.3.

Inspect all the threaded holes for damage. The threads may be reconditioned with thread inserts.14.Inspect the sealing surfaces.15.Inspect the cylinder head cup plugs.16.



Valve Guide Reaming/Valve and Seat GrindingTools Required

J 36019-A Valve Guide Reamer

Ream the valve guides for oversize valves using the J 36019-A if the clearance exceeds the specifications.1.Service valves are available in the standard and 1 mm oversize.2.Ream the valve guide bores for the oversize valves as necessary.3.Reconditioning the valve seats is very important. 4.Recondition the valve seat after reaming the valve guide bores.

Important

Because the valve guide serves to support and center the valve grinder, it is essential that the valve guide is cleaned properly. If the valveguide requires reaming, this must be done first.

Inspect the valve seats for excessive wear and burned spots. Valve seats may be reconditioned by grinding. If grinding results in the newseat being too wide it may be narrowed by using a 20 degree or 70 degree stone. The 20 degree stone will lower the seat and the 70 degreestone will raise the seat.

5.

The valves must seat perfectly for the engine to deliver optimum power and performance.1.Cooling the valve heads is another important factor. Good contact between each valve and its seat in the cylinder head is necessaryto insure that the heat in the valve head is properly carried away.

2.

Regardless of what type of equipment is used, it is essential that the valve guide bores are free from carbon or dirt in order to ensurethe proper centering of the pilot in the guide. The valve seats should be concentric to within 0.05 mm (0.031 in) total indicatorreading.

3.

Do not attempt to reface valves from the Twin Cam engine. Replace any valve that is not in serviceable condition.4.



Cylinder Head AssembleTools RequiredJ 36660-A Torque Angle Meter1.J 8062 Valve Spring Compressor2.J 9666 Valve Spring Tester3.

Install the new cylinder head cup plug if necessary. Coat the plugs with Sealer GM P/N 12345382 or an equivalent.1.

Notice

In order to avoid damage, install the spark plugs after the cylinder head has been installed on the engine.

Install the valve mechanism.2.Install the valve spring retainers.3.

Notice

Clean the valve guides before reaming. Packing of chips or carbon may result in the reamer jamming into the valve guide or broken reamerflutes.

Use the following steps to measure the valve guide clearance:4.With a hole gauge, measure the valve guide ID with a micrometer, measure the valve stem. Compare the valve guide ID and thevalve stem measurements. Refer to engine specifications for allowable clearance.

A.

The valve guides may be reamed oversize and an oversized valve may be installed. Do not knurl the valve guides.B.Inspect the valve springs. Refer to engine specifications for the tolerances.5.

Look for the following conditions when inspecting the valve springs:6.Expanded height1.Unparallel spring ends2.Spring tension using J 9666 .3.

Inspect the valve spring seating surface of the valve rotators and spring seats for wear or gouging. Replace as required.7.Assemble the valves.8.Use the following steps to measure valve runout:9.

Apply a dab of Prussian blue on the entire valve face. Seat the valve, but do not rotate the valve. The Prussian blue tracestransferred to the valve seat are an indication of concentricity of the valve seat.

A.

Clean all traces of Prussian blue.B.Apply a dab of Prussian blue on the valve seat and repeat the check. The traces of Prussian blue transferred to the valve faceindicates valve face concentricity.

C.

Recondition the valve seat or replace the valves, if required.D.Install the rotator (intake valves only).10.

Install the spring valve (intake valves only).11.

Install the new valve seals. Fully seat the seals on the valve guides.12.

Install the spring seat (exhaust valves only).13.Install the spring.14.Install the retainer.15.Compress the valve spring. Use the J 8062 .16.

Install the valve keys.17.Slowly release the J 8062 from the valve/spring assembly.18.Inspect for proper valve key seating.19.

Measure the valve installed height using a ruler. Measure from the base of the valve spring to the top of the valve. Refer to Engine Mechanical Specifications for the correct specification.

20.

Install the remaining valves, springs, and other components.21.

Inspect the O-ring for damage. If the O-ring is damaged, replace the O-ring.22.

Notice


Install the coolant outlet.23.Tighten

Tighten the bolts to 26 N·m (19 lb ft).



Oil Pump Disassemble

Disassemble the oil pump gerotor cover from the oil pump housing.1.Remove the oil pump from the balance shaft housing.2.

Disassemble the pressure relief valve. Remove the roll pin with a punch.3.Clean all of the parts in cleaning solvent. Remove varnish, sludge, and dirt.4.



Oil Pump Cleaning and Inspection

Clean all of the oil pump parts in solvent.1.Inspect the pump cover housing for the following conditions:2.

Cracks1.Scoring2.Porous or damaged casting3.Damaged threads4.Excessive wear or galling5.

Inspect the pressure relief valve for damage. Replace the valve if the valve is damaged.3.Inspect the gerotor for the following conditions:4.

Chipping1.Galling2.Excessive wear3.

Measure the following parts:5.The gerotor cavity depth1.The inner gerotor tip clearance2.The outer gerotor diameter clearance3.The gear dimensions4.

Replace the pump as an assembly if the housing or gears are worn beyond specifications.6.



Oil Pump AssembleLubricate the gerotor gears with clean engine oil.1.

Assemble the gerotor in the housing.2.

Notice

Fill oil pump cavities with petroleum jelly prior to installation. This will ensure that there is oil pressure immediately on start-up and willprevent engine damage.

Fill the oil pump with petroleum jelly to prime the oil pump.3.

Assemble the pressure relief valve.4.

Assemble the pump housing to the balance shaft assembly.5.Assemble the pump cover to the oil pump housing.6.



Engine Front Cover Cleaning and Inspection

Clean all sealing surfaces.1.Inspect all sealing surfaces for burrs and imperfections.2.Inspect the front cover for any cracks.3.Inspect the front cover gasket for any damage. If the gasket is damaged, replace it with a new gasket.4.



Intake Manifold Cleaning and Inspection

Clean the intake manifold mating surfaces.1.Inspect the intake manifold for damage.2.Inspect the intake manifold for cracks near compression limiters.3.Inspect the crankcase ventilation passages in the intake manifold face for blockage and clean as necessary.4.Replace the intake manifold as necessary.5.



Exhaust Manifold Cleaning and Inspection

Important

Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. Aimproperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.

1.

Remove the oxygen sensor prior to cleaning the manifold, do not submerge the oxygen sensor in cleaning solvent.2.

Remove the oxygen sensor from the manifold.1.Clean the exhaust manifold in solvent.2.

Caution


Dry the exhaust manifold with compressed air.3.Inspect for a loose or damaged heat shield.4.

Use a straight edge and a feeler gauge and measure the exhaust manifold mounting face for warpage.5.An exhaust manifold face with warpage in excess of 0.25 mm (0.010 in), may cause an exhaust leak and may effect OBD II systemperformance. Exhaust manifolds not within specifications must be replaced.



Oil Pan Cleaning and Inspection

Clean the oil pan mating surface.1.Clean the oil pan. Remove all the sludge and the oil deposits.2.Inspect the threads for the engine oil drain plug.3.Inspect the oil pan for cracking near the pan rail and the transmission mounting points.4.Inspect the oil pan for cracking resulting from impact or flying road debris.5.Repair or replace the oil pan as necessary.6.



Balance Shaft Cleaning and InspectionBalance Shaft Housing Disassembly

Remove the oil pump pick-up screen. Pry the screen out with a suitable tool.1.

Loosen all of the housing bolts.2.Separate the balance shaft housings.3.Remove the balance shaft and gear subassemblies from the housing.4.

Carefully remove the bearing halves from the housing. Do not scratch or gouge the housing.5.

Remove the thrust plate bolts.6.Remove the thrust plate.7.

Balance Shaft Housing Inspection

Clean all parts in cleaning solvent. Remove varnish, sludge and dirt.1.Inspect the balance shaft housings for the following conditions:2.

Cracks1.Scored bearing bores2.Damaged threaded holes3.

If the housings are damaged in any way, replace the entire assembly.3.

Balance Shaft Chain Cover Inspection

Clean all parts in cleaning solvent. Remove varnish, sludge and dirt.1.Inspect the balance shaft chain cover for the following conditions:2.

Cracks1.Broken or worn guides2.

Balance Shaft Chain Guide Inspection

Clean all of the balance shaft chain guide parts in cleaning solvent. Remove the varnish, sludge, and dirt.1.Inspect the balance shaft chain guide for the following conditions:2.

Plastic worn off of the guide1.Cracks2.Mounting hole damage3.

Replace the balance shaft chain guide if the guide has grooves deeper than 2.0 mm (0.080 in).3.

Balance Shaft Driven Sprocket Inspection

Clean all of the driven sprocket parts in cleaning solvent. Remove the varnish, sludge and dirt.1.Inspect the driven sprocket teeth for the following conditions:2.

Bent teeth1.Broken teeth2.Chips3.Ground off teeth4.

Inspect the driven sprocket for the following conditions:3.

Burrs1.Damaged bolt hole2.Scored surfaces3.

Balance Shaft and Gear Assembly Inspection

Clean all of the balance shaft and gear assembly parts in cleaning solvent. Remove the varnish, sludge and dirt.1.Inspect the balance shaft for the following conditions:2.

Scores on the journals1.Burrs on the journals2.Cracks3.Missing pieces4.

Inspect the gears for the following conditions:3.Missing teeth1.Chipped teeth2.

Notice

Do not attempt to resurface the balance shaft journals. They have a slight taper and resurfacing the journal may remove the taper. The taperis angled towards the counter weights.

Replace both shafts even if only one needs to be replaced. Replace the bearings any time the shafts are replaced.4.Measure the journals for the following conditions:5.

The correct outside diameter1.An out of round condition2.

Measure the gears for backlash using the following procedure:6.Place the gear and the shaft assemblies in the housing. The bearings must be installed. Ensure that the timing marks are aligned.A.Set up the dial indicator to read off of one tooth of the balance shaft gear.B.Hold the other shaft.C.

Important

If the shafts are not pulled in the same direction, the gears will climb away from each other causing the reading to be incorrect. Do notrotate the gear as you will get incorrect readings.

While pulling both shafts in the same direction, gently rock the gear in the direction of the rotation to ensure the proper measurements.7.Note the total movement and compare the movement to specifications.8.Replace both the gear and the shaft assemblies if the backlash is out of specification.9.

Balance Shaft Bearing Inspection

Clean the bearings in cleaning solvent. Remove the varnish, sludge and dirt.1.Inspect the bearings for the following conditions:2.

Gouges1.Scoring2.Discoloration3.

Balance Shaft Bearing Clearance Measurement

Important

Method A yields measurements from which the bearing clearance can be computed. Method B yields the bearing clearance directly. Method Bdoes not indicate bearing or journal runout. Do not mix inserts of different nominal size.

Method AUse a micrometer in order to measure the balance shaft journal diameter in several places approximately 90 degrees apart. Average themeasurements.

1.

Compute the taper and runout to ensure they are within the specification limits.2.Use an inside micrometer in order to measure the bearing insert ID. If you are replacing the inserts, measure using the new inserts.3.Subtract the bearing measurement from the journal diameter in order to get the clearance. Refer to specifications for allowable limits.4.

Method BWipe all of the oil off of the balance shaft journal and the bearing surfaces.1.

Important

Do not rotate the shafts after the gauging plastic has been placed on the journals. If the shafts are rotated the gauging plastic will smear,making the readings wrong.

Place a piece of gauging plastic across the entire journal surface.2.Assemble the upper and lower housings and tighten all the fasteners in sequence to specification.3.Disassemble the housing.4.Measure the flattened plastic at the widest point with the scale on the gauging plastic package. The plastic will be wider on the journal endaway from the counter weight. This is because the journals are purposely tapered.

5.

Remove all of the gauging plastic from the bearing and or journal.6.Compare the measurements to engine specifications.7.

Balance Shaft Thrust Plate Inspection

Clean all parts in cleaning solvent. Remove the varnish, sludge and dirt.1.Inspect the trust plate for the following conditions:2.

Gouges1.Burrs2.

Balance Shaft Drive Chain Inspection

Clean the balance shaft drive chain parts in cleaning solvent. Remove the varnish, sludge and dirt.1.Inspect the balance shaft drive chain for the following conditions:2.

Damaged links1.Worn or missing rollers2.

Notice

Do not attempt to remove a link from the chain. The chain may be weakened and may fail, resulting in a loss of oil pressure and engine

damage.

Replace the chain and sprockets if the chain tension cannot be adjusted to specification before the chain hits the housing or the guidecomes to the end of its travel.

3.

Balance Shaft Drive Sprocket Inspection

Clean all of the drive sprocket parts in cleaning solvent. Remove the varnish, the sludge, and the dirt.1.Inspect the sprocket teeth for the following conditions:2.

Bent teeth1.Broken teeth2.Chips3.Ground off teeth4.

Inspect the sprocket for the following conditions:3.Burrs1.Scored surfaces2.

If the sprocket is to be replaced, inspect the crankshaft for burrs or nicks.4.

Balance Shaft Housing Assembly

Install the thrust plate.1.

Notice


Install the thrust plate bolts.2.Tighten

Tighten the thrust plate bolts to 13 N·m (115 lb in).

Carefully install the bearing halves into the housing. Do not scratch or gouge the housing or the bearings.3.Lubricate the bearings, shafts and gears with GM P/N 9985705 or an equivalent.4.

Install the balance shaft and gear assemblies into the housing.5.Ensure that the timing marks on the balance shaft gears are lined up.6.Install the upper housing half to the lower housing half.7.Install the housing fasteners.8.Tighten

Tighten the fasteners to 5 N·m (44 lb in).

Important

Do not install the oil pump pick-up screen until the housing fasteners have been tightened to final specifications.

Tighten the fasteners to final specifications after the housing assembly has been installed on the engine.9.



Service Prior to AssemblyThe importance of cleanliness during assembly cannot be overstated. Dirt or debris will cause engine damage. An automobile engine is acombination of many machined, honed, polished and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When anyinternal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas duringassembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, it should be understood that proper cleaningand protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if notspecifically stated.

Lubricate all moving parts with engine oil or a specified assembly lubricant. This will provide lubrication for initial start up.



Engine Block Plug Installation

Apply gasket paste GM P/N United States 12346004, GM P/N Canada 10953480 to the plug.1.Install the engine block coolant drain plug.2.

Notice


Install the coolant jacket plug.3.Tighten

Tighten the coolant jacket plug to 30 N·m (22 lb ft).

Apply gasket paste GM P/N United States 12346004, GM P/N Canada 10953480 to the plug.4.Install the timing chain tensioner gallery oil passage plug.5.Tighten

Tighten the oil passage plug to 20 N·m (15 lb ft).

Apply gasket paste GM P/N United States 12346004, GM P/N Canada 10953480 to the plug.6.Install the rear oil passage plug.7.Tighten

Tighten the oil passage plug to 10 N·m (89 lb in).

Apply gasket paste GM P/N United States 12346004, GM P/N Canada 10953480 to the plug.8.Install the front oil passage plug.9.Tighten


Apply gasket paste GM P/N United States 12346004, GM P/N Canada 10953480 to the plug.10.Install the rignt side oil passage plug.11.Tighten


Install a new oil flow check valve in the oil passage for the cylinder head.12.Drive the check valve in until the valve is flush with the cylinder block headgasket surface.13.



Crankshaft and Bearings InstallationTools Required

J 36660-A Torque Angle Meter

Install the main bearings and lubricate with engine oil.1.Install the crankshaft on the journals.2.

Notice

In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into thecylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the

crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap.

Install the crankshaft caps. Tap gently into place with a suitable tool.3.Install the crankshaft cap bolts. Finger tighten the bolts.4.

Notice


Seat the crankshaft thrust bearing.5.Tighten

Tighten the bearing cap bolts to 20 N·m (15 lb ft), and rotate the bolts 90 degrees, using the J 36660-A .


Crankshaft Rear Oil Seal and Housing InstallationTools Required

J 36005 Rear Main Seal Installer

Press the new crankshaft seal into the housing, using the J 36005 . The installer also establishes the depth of the seal in the housing.1.Position the new seal housing to block the gasket over the alignment dowel pins. The gasket is reversible.2.Lubricate the lip of the crankshaft seal with engine oil.3.Install the seal housing assembly.4.

Notice


Install the seal housing to block bolts.5.Tighten

Tighten the bolts to 12 N·m (106 lb in).



Piston, Connecting Rod, and Bearing InstallationTools RequiredJ 36660-A Torque Angle Meter1.J 8037 Piston Ring Compressor2.

Install the connecting rod bearings. Use the proper size bearings.1.Install the bearing inserts into the connecting rod and the connecting rod cap.A.Lubricate the connecting rod bearings with engine oil.B.

Install the piston and the connecting rod to the correct bore.2.Slide a piece of 9.5 mm (0.375 in) fuel or vacuum hose over the connecting rod bolts. This protects the crankshaft journal duringpiston and connecting rod installation.

A.

Stagger each piston ring end gap equally around the piston.B.Lubricate the piston and the piston rings with engine oil.C.

Install J 8037 over the piston. Do not disturb the piston ring end gap location.D.The piston must be installed so that the mark on the top of the piston faces the front of the engine.E.Place the piston in its matching bore. F.Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the pistoninto place.

G.

Hold the J 8037 against the engine block until all the rings have entered the cylinder bore.H.Remove the vacuum hose from the connecting rod bolts.I.

Important

Ensure that the connecting rod cap is properly oriented on the connecting rod.

Install the connecting rod cap.3.

Notice


Install the connecting rod bolt nuts.4.Tighten

Tighten the connecting rod bolt nuts to 25 N·m (18 lb ft), then rotate 80 degrees using the J 36660-A .a.Install the remaining connecting rods and piston assemblies.b.

Measure the connecting rod side clearance with a feeler gauge.5.The correct clearance is 0.150-0.450 mm (0.0059-0.0177 in).Install the crankshaft timing sprocket with the marked side facing out and rotate the crankshaft to align the keyway with the timing markon the engine block.

6.



Balance Shaft Housing InstallationTools RequiredJ 41088 Balance Shaft Holder1.J 36660-A Torque Angle Meter2.

Install the balance shaft assembly to the block.1.Apply GM P/N United States 12345493, GM P/N Canada 10953488 or the equivalent on the housing assembly to the block bolts.2.If the balance shaft housing was disassembled, loosely assemble the housing assembly to the block.3.

Notice


Tighten the housing fasteners in sequence.4.Tighten

Tighten fasteners 1, 2, 4, 5, 6 and 7 to 15 N·m (11 lb ft) + 40 degrees.1.Tighten fasteners 3 and 8 to 10 N·m (89 lb in) + 40 degrees.2.

Tighten the housing assembly to block bolts in sequence.5.Tighten

Tighten bolts 1, 2, and 4 to 25 N·m (18 lb ft) + 70 degrees.1.Tighten bolt 3 to 40 N·m (30 lb in) + 60 degrees.2.Tighten bolt 5 to 53 N·m (39 lb ft).3.

Ensure that the balance shafts spin freely.6.If the balance shaft housing was disassembled, install the oil pump pick-up screen into the housing. Lightly tap the oil pump pick-upscreen into place with a plastic hammer.

7.

Important

If the balance shafts are not properly timed to the engine, the engine may vibrate or make noise.

Use the following steps to time the balance shaft to the engine:8.Place the number one piston at TDC.A.Rotate the crankshaft 90 degrees.B.Install the J 41088 on to the balance shaft assembly in order to ensure that the shafts do not rotate while the driven sprocket bolt istightened.

C.

Important

The surface that was marked during disassembly of the driven sprocket must show if the drive sprocket is going to be reused. This willinsure that the chain continues to ride on the same surface. If a new driven sprocket will be installed, either surface can be placed againstthe shaft.

Install the driven sprocket to the shaft.9.

Important

The balance shaft driven sprocket bolt is left hand threaded and must be tightened by rotating the bolt in a counter clockwise direction.

Install the balance shaft driven sprocket bolt. Finger tighten the bolt.10.

Install the balance shaft chain guide.11.Press the chain guide tightly against the chain.12.Tighten the chain tensioner bolt.13.Tighten

Tighten the bolt to 13 N·m (115 lb in).

Tighten the balance shaft driven sprocket bolt.14.Tighten

Tighten the bolt to 40 N·m (30 lb ft) and rotate the bolt 45 degrees.

Remove the J 41088 from the balance shaft housing assembly.15.Loosen the balance shaft chain guide bolt.16.

Important

A brass feeler gauge needs to be used to ensure correct measurements are obtained. If a steel gauge is used, the steel gauge will not bendto conform to the guide and will cause incorrect measurements.

Use the following procedure to adjust the balance shaft drive chain tension:17.Inserting a 1 mm (0.040 in) brass feeler gauge between the chain guide and the chain.A.Press the guide against the chain. Use about three pounds of force.B.Tighten the chain fastener bolt.C.Tighten


Install the balance shaft chain cover.18.Install the balance shaft chain cover nut and bolt.19.Tighten

Tighten the nut and bolt to 13 N·m (115 lb in).



Oil Pump Installation

Install the oil pump cover to the balance shaft housing.1.

Notice


Install the oil pump bolts to the balance shaft housing.2.

TightenTighten the pump to housing long bolts to 12 N·m (2.69 lb in).1.Tighten the pump to housing short bolts to 10 N·m (2.24 lb in).2.

Install the balance shaft chain guide.3.

Important

A brass feeler gauge needs to be used to ensure correct measurements are obtained. If a steel gauge is used, the steel gauge will not bendto conform to the guide and will cause incorrect measurements.

Use the following procedure to adjust the balance shaft drive chain tension:4.Inserting a 1 mm (0.040 in) brass feeler gauge between the chain guide and the chain.A.Press the guide against the chain. Use about three pounds of force.B.Tighten the chain fastener bolt.C.Tighten


Install the balance shaft chain cover.5.

Install the balance shaft chain cover nut and bolt.6.Tighten

Tighten the nut and bolt to 13 N·m (115 lb in).



Timing Balance Shafts to EngineTools RequiredJ 41088 Balance Shaft Holder1.J 36660-A Torque Angle Meter2.

Important

If the balance shafts are not properly timed to the engine, the engine may vibrate or make noise.

Install and time the balance shaft assembly to the engine using the following steps:1.Place the number one piston at TDC.A.

Rotate the crankshaft clockwise 90 degrees in either direction from TDC (viewing the crankshaft from the front of the engine)B.Install the J 41088 on to the balance shaft assembly to ensure the shafts do not rotate while the driven sprocket bolt is tightened.C.

Notice

A new balance shaft driven sprocket bolt must be used any time the bolt is removed. If a new bolt is not used, the balance shaft sprocketmay slip allowing the balance shafts to become mistimed and cause engine vibration.

Important

The surface that was marked during disassembly of the driven sprocket must show if the drive sprocket is going to be reused. This willinsure that the chain continues to ride on the same surface. If a new driven sprocket will be installed, either surface can be placed againstthe shaft.

Install the driven sprocket to the shaft.2.

Important

The balance shaft driven sprocket bolt is left hand threaded and must be tightened by rotating the bolt in a counter clockwise direction.

Install the driven sprocket bolt. Finger tighten the bolt.3.

Install the balance shaft chain guide.4.Press the chain guide tightly against the chain.5.

Notice


Tighten the chain tensioner bolt.6.Tighten

Tighten the chain tensioner bolt to 13 N·m (115 lb in).

Tighten the balance shaft driven sprocket bolt.7.Tighten

Tighten the driven sprocket bolt to 40 N·m (30 lb ft). Use the J 36660-A in order to rotate the bolt an additional 45 degrees.

Remove the J 41088 from the balance shaft housing assembly.8.Loosen the balance shaft chain guide bolt.9.

Important

A brass feeler gauge needs to be used in order to ensure correct measurements are obtained. If a steel gauge is used, the steel gauge willnot bend to conform to the guide and will cause incorrect measurements.

Adjust the balance shaft drive chain tension. Insert a 1 mm (0.040 in) brass feeler gauge between the chain guide and the chain.10.Press the guide against the chain using about three pounds of force.11.Install the chain tensioner bolt.12.Tighten

Tighten the chain tensioner bolt to 13 N·m (115 lb in).

Install the balance shaft chain cover.13.Install the balance shaft chain cover nut and bolt.14.Tighten

Tighten the chain cover nut and bolt to 13 N·m (115 lb in).



Cylinder Head InstallationTools Required


Install the cylinder head gasket to the block.1.

Important

Do not use any sealing material.

Install the cylinder head.2.

Lightly apply clean engine oil to the threads and the bottom side of the flange of the head bolt and allow the oil to drain before installing.3.

Notice


Install and tighten the cylinder head bolts in sequence.4.Tighten

Tighten bolts 1-8 to 65 N·m (40 lb ft).1.Tighten bolts 9 and 10 to 40 N·m (30 lb ft).2.Then turn all the bolts an additional 90 degrees in sequence, using the J 36660-A .3.



Intake Camshaft, Housing and Lifter InstallationTools Required

J 36660-A Torque/Angle Meter

Important

Ensure that the camshaft housing alignment dowel pins are in the cylinder head prior to installing the housing.

Install the camshaft carrier dowel pins in the cylinder head.1.

Install the camshaft housing to the cylinder head with a new gasket.2.Sealer is unnecessary.Loosely install one camshaft housing to the cylinder head bolt in order to hold the housing in place.3.

Important

Used lifters must be returned to the original position in the camshaft housing.1.If the camshaft is being replaced, the lifters actuated by the camshaft must also be replaced.2.

Install the lifters into the lifter bores.4.

Notice

The camshaft lobes and the journals must be adequately lubricated or serious engine damage will occur upon start up.

Lube the camshaft lobe and journals with the camshaft and lifter prelube GM P/N United States 12345501, GM P/N Canada 992704 orthe equivalent.

5.

Install the camshaft in the same position as when removed.6.The timing chain sprocket dowel pin should be straight up and line up with the centerline of the lifter bores.

Install the new camshaft housing to the green colored camshaft housing cover seals and into the cover.7.Sealant is unnecessary.Remove the loose bolt holding the housing in place.8.

Install the camshaft housing cover to the camshaft housing.9.

Notice


Important

The top intake camshaft housing bolts are tightened to a different specification than the other camshaft housing bolts.

Using the J 36660-A , install and tighten the bolts in sequence.10.Rotate the bolts the amount of degrees specified in sequence. Tighten

Tighten the camshaft housing to cylinder head bolts to 22 N·m (16 lb ft) + 90 degrees.1.Tighten the camshaft housing cover to camshaft housing bolts to 22 N·m (16 lb ft) + 30 degrees.2.

Important

When reinstalling the power steering pump, apply a 3 mm bead of GM P/N United States 12346286, GM P/N Canada 10953472 sealeror the equivalent to the joint at the end of the camshaft housing halves before the installation of the power steering pump and the pumpface seal.

Install the power steering pump assembly.11.



Exhaust Camshaft, Housing and Lifter InstallationTools Required

J 36660-A Torque/Angle Meter

Important

Ensure that the camshaft housing alignment dowel pins are in the cylinder head prior to installing the housing.

Install the camshaft carrier dowel pins in the cylinder head.1.

Install the camshaft housing to the cylinder head with a new gasket.2.Sealer is unnecessary.Loosely install one camshaft housing to the cylinder head bolt in order to hold the housing in place.3.

Important

Used lifters must be returned to their original position in the camshaft housing.1.If the camshaft is being replaced, the lifters must also be replaced.2.

Install the lifters into the lifter bores.4.

Notice

The camshaft lobes and the journals must be adequately lubricated or serious engine damage will occur upon start up.

Lube the camshaft lobes and the journals with the Camshaft and Lifter Prelube GM P/N United States 12345501,GM P/N Canada 992704 or the equivalent.

5.

Install the camshaft in the same position as when removed.6.The timing chain sprocket dowel pin should be straight up and line up with the centerline of the lifter bores.

Install the new camshaft housing to the orange camshaft housing cover seals into the cover.7.Sealer is unnecessary.Remove the bolt holding the housing in place.8.

Install the camshaft housing cover to the camshaft housing.9.

Notice


Use the J 36660-A , install and tighten the bolts in sequence.10.Rotate the bolts the amount of degrees specified in sequence. Tighten

Tighten the camshaft housing to cylinder head bolts to 15 N·m (11 lb ft) + 90 degrees.1.Tighten the camshaft housing cover to camshaft housing bolts to 15 N·m (11 lb ft) + 30 degrees.2.



Timing Chain Housing InstallationTool Required

J 36008-A Camshaft Timing Pins

Important

Ensure that the alignment pins are in the cylinder block and the timing chain housing, before installing the timing chain housing. Thealignment pins ensure proper chain housing and front cover location for correct front oil seal-to-crankshaft alignment.

Important

Ensure that the timing chain housing to camshaft housing gaskets are properly oriented. If the gaskets are not properly oriented an oil leakwill result.

Install the timing chain housing gaskets. 1.Install the timing chain housing. No sealer is needed.2.Install the timing chain housing to the camshaft housing bolts and hand tighten.3.Install the timing chain housing to the block fasteners and hand tighten.4.

Notice


Install the chain housing to the oil pan bolts and hand tighten.5.

Tighten the bolts.6.Tighten

Tighten the (M8 X 1.25 X 25) (1) to 26 N·m (19 lb ft).1.Tighten the (M10 X 1.25 X 55) (2) to 50 N·m (37 lb ft).2.Tighten the (M8 X 1.25 X 25) (3) to 29 N·m (21 lb ft).3.

Install the camshaft sprockets. Sprockets are identical and interchangeable.7.Clean the old sealer off of the bolt with a wire brush.8.Clean the threaded hole in the camshaft with a nylon bristle brush.9.Install the camshaft sprocket bolts and washers while holding the sprockets with J 36008-A .10.Tighten


Use Adhesive/Sealant Compound GM P/N United States 12345493, GM P/N Canada 10953488 or the equivalent on the camshaftsprocket bolts.

11.



Water Pump InstallationImportant

Use the following guidelines when servicing the cooling system or draining the cooling system for service procedures:

Add 2 coolant pellets, GM P/N 3634621 or an equivalent, when the cooling system is serviced or drain for service procedures.1.The pellets must be added to the radiator or the pressurized water reservoir.2.Crush the pellets prior to installation.3.Do not place the pellets into a non-pressurized coolant recovery reservoir. On these systems, the pellets must be added to the radiator.4.The sealant pellets may leave a film on the sides of the pressurized and non-pressurized water recovery reservoirs. This film is normal.5.

Prior to installing the water pump read the entire procedure. Pay special attention to the tightening sequence to avoid part damage and to ensureproper sealing.

Install the water pump cover to the coolant pump assembly.1.Install the water pump bolts. Finger tighten the bolts.2.Install the cover to the block bolts. Finger tighten the bolts.3.Install the pump to chain housing nuts. Finger tighten the nuts.4.

Notice


Use the following sequence to tighten the fasteners:5.Install the pump assembly to the chain housing nuts.A.Tighten

Tighten the nuts to 26 N·m (19 lb ft).

Install the pump cover to the pump assembly.B.Tighten


Install the cover to the block, bottom bolt first.C.Tighten




Timing Chain, Sprockets, Tensioner InstallationTools RequiredJ 36008-A Camshaft Sprocket Alignment Pins1.J 39579 Camshaft Gear Holder2.

Install the camshaft sprockets. The sprockets are identical and interchangeable.1.Clean the old sealer off of the bolts with a wire brush.2.Clean the threaded hole in the camshaft with a nylon bristle brush.3.Coat the camshaft sprocket bolts with Threadlocker GM P/N United States 12345493, GM P/N Canada 10953488 or the equivalent.4.

Notice


Install the camshaft sprocket bolts and washers while holding the sprockets with J 39579 .5.Tighten


Important

Ensure that the camshaft sprocket alignment pins are in the cylinder block and the timing chain housing, prior to installing the timing chainhousing. The camshaft sprocket alignment pins ensure proper chain housing and front cover location for correct frontoil-seal-to-crankshaft alignment.

Install the J 36008-A through the holes in the camshaft sprockets and into the holes in the timing chain housing. This will position the6.

camshaft for correct timing.Use the following steps if the camshafts are out of position and must be rotated more than 1/8 turn in order to install the alignment dowelpins:

7.

Notice

Failure to follow this procedure could result in severe engine damage.

The crankshaft must be rotated 90 degrees clockwise off of TDC to give the valves adequate clearance to open.A.Once the camshafts are in position and the dowels are installed, rotate the crankshaft counter-clockwise back to TDC.B.

Notice

Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur.

Important

The timing chain and crankshaft sprocket must be put on in a specific direction for chain noise and wear considerations. The surfaces thatwere marked during removal should be showing when the chain and crankshaft sprocket are installed.

Install the timing chain over the exhaust camshaft sprocket around the coolant pump sprocket and around the crankshaft sprocket.8.Remove the alignment dowel pin from the intake camshaft. Use the J 39579 in order to rotate the intake camshaft sprocketcounter-clockwise enough to allow the timing chain to slide over the intake camshaft sprocket.

9.

Release the J 39579 . The length of the chain between the 2 camshaft sprockets will tighten.10.If properly timed, the intake camshaft alignment dowel pin will slide in easily. If the dowel pin does not fully index, the camshafts are nottimed correctly and the procedure must be repeated.

11.

Leave the alignment dowel pins installed.12.The keyway on the crankshaft and the mark on the cylinder block should be aligned with the slack removed from the chain between theintake camshaft sprocket and the crankshaft sprocket. If the mark and the keyway are not aligned, move the chain 1 tooth forward orrearward. Remove the slack and recheck the marks.

13.

Important

Use the following steps in order to reset the timing chain tensioner assembly to the zero position:

Reset the timing chain tensioner assembly.14.Insert the tensioner plunger assembly into the tensioner housing.A.With the tensioner plunger fully extended, turn the complete assembly upside down on a bench or other flat surface.B.With the plunger face against the workbench, press firmly on the bottom of the tensioner housing.C.Compress the plunger until the plunger is seated flush in the tensioner.D.

Check the plunger to make sure that the plunger is out of the cylinder at the correct dimension.15.The correct dimension for the plunger to extend out of the cylinder is 1.7 mm (0.07 in) maximum.

Loosely install the tensioner assembly and bolts to the timing chain housing.16.Install the timing chain tensioner shoe on the stud.17.Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud.18.Tighten the timing chain tensioner bolts. Do not over tighten.19.Tighten


Important

If the timing chain tensioner plunger is not released from the installation position, engine damage will occur when the engine is started.

Release the timing chain tensioner plunger.20.Using a flat blade screwdriver, cotter pin remover, or a similar tool, press firmly against the face of the timing chain tensionerplunger.

A.

Important

If the timing chain tensioner plunger cannot be depressed, the plunger is not properly reset and the procedure for resetting the timingchain tensioner should be repeated.

Depress the timing chain tensioner plunger until the plunger is bottomed out in the bore of the timing chain tensioner.B.Release the tensioner plunger. The plunger should press firmly against the back of the timing chain tensioner shoe.C.

Remove the J 36008-A from the camshaft sprockets.21.

Notice

The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timingsprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrongtiming chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled in the same side facing outat the time of reassembly.

Rotate the crankshaft clockwise 2 full rotations. Align the crankshaft keyway with the mark on the cylinder block and reinstall thealignment dowel pins. The alignment dowel pins will slide in easily if the engine is timed correctly.

22.

Install the timing chain guides.23.


Crankshaft Front Cover Oil Seal InstallationTool Required

J 36010 Front Crankshaft Seal Installer

Install the seal into the front cover by driving the seal in from the timing chain side using the J 36010 . The J 36010 will properly positionthe seal in the front cover.

1.

Ensure that the engine front cover is properly supported when installing the seal.2.



Engine Front Cover InstallationTools Required


Install the front cover gasket. The gasket is reusable and does not require sealer.1.Inspect the front cover gasket for damage before reusing the gasket.2.

Notice

Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fastenersrequiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not

use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torqueand joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners inorder to avoid damage to parts and systems.

Install the upper front cover bolts.3.Tighten

Tighten the engine front cover bolts to 12 N·m (106 lb in).

Install the engine front cover nuts.4.Tighten

Tighten the fasteners to 12 N·m (106 lb in).

Lubricate the front oil seal with Chassis Grease GM P/N United States 1051344, GM P/N Canada 993037 or the equivalent.5.



Oil Pan Installation

Inspect the oil pan gasket for damage, replace as necessary. The oil pan gasket is reusable.1.Install the oil pan gasket.2.Install the oil pan.3.

Install the oil pan bolts and hand tighten.4.

Notice


Tighten the oil pan bolts.5.Tighten

Tighten the (M8 X 1.25 X 80) (1) to 24 N·m (18 lb ft).1.Tighten the (M8 X 1.25 X 22) (2) to 24 N·m (18 lb ft).2.Tighten the (M6 X 1.00 X 25) (3) to 12 N·m (106 lb in).3.Tighten the (4) to 26 N·m (19 lb ft).4.



Oil Filter Adapter Installation

Install the oil filter bypass valve.1.Insert the new oil filter bypass valve in the cylinder block.A.Use a center punch to stake the valve in three places.B.

Notice


Install the oil filter adapter.2.Tighten

Tighten the oil filter adapter to 29 N·m (21 lb ft).

Install a new oil filter.3.Lubricate the oil filter seal with clean engine oil before installation.A.Tighten the oil filter 3/4 to one full turn after the gasket contacts the cylinder block.B.



Intake Manifold Installation

Notice

Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold ismade of a composite plastic and can be damaged if it is removed when the engine is hot.

Install the new gasket with the numbers stamped on the gasket faced toward the manifold surface.1.Install the intake manifold gasket. The gasket is reusable if the gasket is undamaged.2.

Install the intake manifold.3.

Notice


Install the intake manifold bolts and nuts. Follow the tightening sequence.4.Tighten

Tighten the bolts and nuts to 22 N·m (16 lb ft).

Install the throttle body.5.Tighten

Tighten the bolts and nuts to 10 N·m (89 lb in).



Crankshaft Balancer InstallationTools Required

J 38122-A Harmonic Balancer Holder

Lubricate the front oil seal and sealing surface of the crankshaft balancer. Use Chassis Grease GM P/N United States 1051344,GM P/N Canada 993037 or the equivalent.

1.

Install the balancer onto the crankshaft indexing keyway. Tap the balancer into place using a rubber or sand filled mallet.2.

Notice

Do not use the J 36660 Torque Angle Meter to rotate the retaining bolt an additional 90 degrees. The torque capacity of the tool will be

exceeded and damage to the tool will result.

Notice


Important

Use the J 38122-A to prevent the crankshaft from rotating.

Install the retaining bolt and washer.3.Tighten

Tighten the bolt to 175 N·m (129 lb ft).

Put a mark on the socket next to one of the four marks on the J 38122-A .4.This mark will represent the zero point or 0 degrees.1.Tighten the bolt by rotating the socket clockwise 90 degrees.2.At 90 degrees the socket indexes with the next mark on the tool.3.



Exhaust Manifold Installation

Install the exhaust manifold gasket.1.Install the exhaust manifold.2.

Notice


Install the exhaust manifold to the cylinder head retaining nuts. Follow the tightening sequence.3.Tighten

Tighten the nuts to 13 N·m (115 lb in).

Install the exhaust manifold upper heat shield.4.Install the exhaust manifold upper heat shield bolts.5.Tighten


Install the exhaust manifold brace to the exhaust manifold.6.Install the exhaust manifold brace to the exhaust manifold bolt.7.Tighten

Tighten the bolt to 56 N·m (41 lb ft).

Install the exhaust manifold brace to the oil pan.8.Install the exhaust manifold brace to the oil pan nuts.9.Tighten

Tighten the nuts to 26 N·m (19 lb ft).



Oil Level Indicator and Tube Installation

Install the tube into the block.1.

Notice


Install the indicator tube bracket to the rear cam carrier lift bracket bolt.2.

Tighten

Tighten the nut to 10 N·m (89 lb in).



Engine Flywheel InstallationTools RequiredJ 36660-A Torque Angle Meter1.J 38122-A Harmonic Balancer Holder2.

Install the flywheel.1.

Install the retainer if the vehicle has an automatic transmission.2.

Notice

This bolt is designed to permanently stretch when tightened. The correct part number fastener must be used to replace this type of fastener.Do not use a bolt that is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The system orthe components may be damaged.

Install the new bolts or apply Adhesive/Sealant Compound GM P/N United States 12345493, GM P/N Canada 10953488 or theequivalent to all flywheel to crankshaft bolts that are being re-used. Carefully follow the instructions included with the thread lockingcompound in order to ensure proper bolt retention.

3.

Notice


Holding the crankshaft balancer with the J 38122-A , tighten the bolts evenly.4.Tighten

Tighten the bolts to 30 N·m (22 lb ft). Use the J 36660-A in order to rotate the bolts 45 degrees.



Engine Set-Up and TestingAfter assembly, test the engine before installing the engine in the vehicle if possible. If a test stand is not available, use the following procedure:

Fill the crankcase with oil.1.If a new camshaft and lifters have been installed, add engine oil supplement GM P/N 1052367 to the engine oil.2.Fill the cooling system with coolant. 3.Add cooling system sealing pellets GM P/N 3634621 to the engine cooling system.4.

Add the pellets directly to the radiator or pressurized coolant reservoir on systems that do not have caps on the radiator.1.Crush the pellets before installation.2.

Crank the engine several times and listen for unusual noises or any other evidence of mechanical problems.5.Start the engine.6.Listen for any abnormal engine sounds.7.Run the engine at 1,000 RPM until the engine is at operating temperature.8.After the engine is at operating temperature, shut the engine off.9.Inspect the engine carefully for oil or coolant leaks.10.


2.4 ld9 engine overhaul procedures ... - ion …- back forward -> document id# 589176 2000...

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